Thixomolding of Magnesium - Efficient Process Industrialization by Combining a Digital Twin and Systematic Casting Trials

Abstract

Besides the realization of the technical specification of a casting, aspects such as resource minimization, cost awareness and robustness of the defined quality requirements are taking major priority, especially in the current global economic situation. Lightweight design, in that respect, is a central topic far beyond the automotive industry and characterizes in particular the ongoing research and development of innovative magnesium cast components. As a resource-efficient alternative to traditional die casting, magnesium-thixomolding offers the benefit of low energy consumption and eschews the necessity of protective gases. The identification of significant influencing factors between process settings, shear and time dependent material properties of semi-solid magnesium, the machine capabilities and the resulting casting quality are the basis for effective product and process design of magnesium thixomolding. Obtaining this knowledge is only possible through methodical process analysis and systematic design of experiments. YIZUMI Germany, together with MAGMA, demonstrates the methodical evaluation of a reliable process window for an AZ91D magnesium “box” component, using a demo mold on a UN1250MGII thixomolding machine. The work shows how a systematic combination of virtual and real casting experiments is used to identify a concrete process layout and generate important knowledge on process variations, robustness as well as control limits. In particular, the comparison of virtual and real casting experiments using statistical methods generates a comprehensive understanding of the impact and limits of different process variables, such as fraction solid, mold temperature and injection speeds. Furthermore it is possible to predict the influence of the gating and component design on the process. The methodological use of qualified casting simulation enables the development of an optimized component design and the determination of a suitable process window with minimized economic or productive risks long before the first component is manufactured – a step towards more resource efficiency and sustainability!